AD-301 Introduction of Fundamental and Designing

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HAPTER

1DEFINITION OF ENGINEERING DESIGN1.1Introduction:

The economic future of India depends on our ability to design, make and sellcompetitive products. Excellent design and effective manufacture are the pre-requisites of asuccessive industry. There is a general impression that the quality of Indian products can stillbe improved. The fact that consumers have lost their confidence on Indian-made productscannot be denied. This problem can be solved only by designing and manufacturing better products through improved methodology. Keeping this in view, the subject “Design andmanufacturing” purpose to present the methods and procedures of design and manufacture.Although engineers are not the only people who design things, the professionalpractice of engineering is largely concerned with design. It is usually said that design is theessence of engineering.The ability to design is both a science and an art. The science can be learned throughprocedures developed by eminent scholars. But the art can be learned only by doing design.

1.2 Types of Products

A product is the tangible end result of a manufacturing process and is meant for satisfying human needs. The product can be classified as follows: -1.Convenience goodsThese are less expensive and are clustered around shops and restaurants. These canbe purchased at consumer’s convenience.E.g. Cigarette, Candy, Magazines etc.2. Shopping goodsThese are expensive and people buy it less frequently.E.g. Jewellary garments etc.3. Specialty goodsThese are purchased, taking extra pain.E.g. Rare objects like stamps.4. Industrial goods.These are items used in the production of other items.Eg. Raw materials.Another way of classifying products is into,(a) Continuous Products, and(b) Discrete productsThe continuous products are those which are produced in a continuous fashion. For example, plates, sheets, tubes and bars etc are produced in very long lengths, and thenthese are cut into desired lengths.On the other hand, discrete products are produced one after another, each in separateunits.On the basis of the output product, the Industry is usually named as continuous industry anddiscrete industry.

1.3 Requirements in a good product

1.Customer Satisfaction2.Profit

How to achieve customer satisfaction?

-The product should function properly.-It must have desired accuracy-It must have desired reliability-It must be easy to operate

-It must be serviceable-It must make minimum space utilization-It must withstand rough handling-Pleasant appearances.-Reasonable price.

How can it be profitable?

-It must be easy to manufacture-The raw material must be cheap and easily available-The manufacturing process has to the decided on the basis of quantity to beproduced-It must use standard parts-It must be easy to pack and distribute.

1.4 Definition of Design: (S ‘94)

Designing is such a vast field that it is defined in several ways. Various definitions of designing as pronounced by well-known designers are

“Design is that which defines solutions to problem which have previously been solved in a different way”

“

Design is the conscious human process of planning physical things that display a new form in response to some pre-determined need”.“Design is an act of collecting all pertinent information for the production of goods and services to meet some human need”.

The design of any component includes two things,(i)Product design(ii)Process designThe product design involves the development of specification for a product that will befunctionally sound, good in appearance, and will give satisfactory performance for anadequate life.The process design involves developing methods of manufacture of the products sothat the component can be produced at a reasonably low cost.

1.5 History of Design Process

(i)Design by Single Person(ii)Over-the-wall design(iii)Simultaneous Engineering(iv)Concurrent Engineering(v)Integrated design and Manufacture.In olden times one person could design and manufacture an entire product. Even for alarge project such as the design of a ship or a bridge, one person had sufficient knowledge of the Physics, Materials and manufacturing processes to manage all aspects of the design andconstruction of the project. This period is referred to as the period of design by single personin the history of design.

CustomersMarketingEngg.DesignProduction

By the middle of the 20th century products and manufacturing processes became socomplex that, one person could not handle all aspects of design and manufacturing. Thissituation led to over-the-wall design process.In this method each functional departments were separated from others, as shown bywall. There was only one-way communications between Customer, Marketing, Engg. Designand production department. The customers ‘throw’ their needs to marketing department. Themarketing department may throw the customer needs to the design department, in manyinstances, orally. The Engg. Design department may conceive a design and hands it over tothe manufacturing sections. The manufacturing department interprets that design and makesthe product according to what they think suitable. Unfortunately, often what is manufacturedby a company using over-the-wall process is not what the customers had in mind. This is dueto lack of interaction between the different departments. Thus, this single direction over-the-wall approach is inefficient and costly and may result in poor quality products.By the early 1980’s the concept of simultaneous engineering emerged. Thisphilosophy emphasized simultaneous development of the manufacturing process- the goalwas the simultaneous development of the product and the manufacturing process. This wasaccomplished by assigning manufacturing representatives to be members of design team, sothat they could interact with the design engineers throughout the designs process.In the 1980’s the simultaneous design philosophy was broadened and calledconcurrent engineering. A short definition of concurrent engineering is the simultaneousprogression of all aspects, at all stages of product development, product specification,design, process and equipment etc. In concurrent engineering the primary focus is on theintegration of teams of people having a stake in the product, design tools, and techniquesand information about the product and the processes used to develop and manufacture it.Tools and techniques connect the teams with the information. Although many of the tools arecomputer-based, much design work is still done with pencil and paper. In fact, concurrentengineering is 80% company culture and 20% computer support.With the advent of computer technology, drastic changes have taken place in the fieldof design and manufacturing. The result was a completely integrated design andmanufacturing system. This system makes a good use of technologies such as CAD/CAM,FMS etc. The computer integrated manufacturing systems (CIMS) moves towards the‘Factory of the future’. CIMS is necessary for better quality, efficiency and productivity.

QUESTIONS

1.How can you explain the term design? Explain the process of mechanical design. Discussthe role of creativity in the design process (S’94, 8M)2.The design of product is …..........customer expectations. (S’99, S’94)3..…………get first preference in designAns. Functional requirements (S’93)4.Explain the meaning of (i)Conceptual design(ii)Functional design(iii) Production design. Give suitable examples for each. (S’03)

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Upload Date:	02/26/2008
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